Carver 57 Voyager Manual

PartNumber999120001/26/0557 / 56 / 53 Voyager Setup Page1of 11
1. Install props and rudders; install
starboard side steering linkage first.
Make sure rudder cotter keys are
installed.
2. Remove fiberglass shipping top from
deck. Also remove plastic off bridge.
Remove tape and clean areas where
bridge will set. Check for voids
along the top of the windows.
3. Apply sealant (white Sikaflex)
supplied in MAC kit, #8105901,
around deck where bridge will set.
Also check for voids in foam above
patio door.
NOTE: Refer to attached pictures
for sealant and sealant tape place-
ment. Apply sealant just prior to
setting bridge.
Also apply Sikaflex on top of the
poly strips located on the deck top.
4. The lifting points for the bridge are
the two lifting eyes each on the front
and aft of the bridge. Set bridge in
position over boat with bow down
resting in front of stern of bridge up
about 16”. Long white plastic di-
vider board should be laid on
portside of deck where bridge seats
sit prior to setting bridge down.
NOTE: If this is not done, you will
not be able to put the divider board
under the seats.
5. Run all wires up through bridge.
a. Connect davit wires and light
wires at port stern corner of
bridge.
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b. Pull coiled water drain hoses down
through holes in bridge and route
through holes in black air intake
vents.
c. Attach hoses to thru-hull fittings on
port and starboard side of boat in aft
engine compartment.
6. Set bridge in place; make sure hoses
and wires don’t get pinched.
7. With bridge set down in place, begin
securing it with fasteners supplied in
MAC kit.
a. Start by pulling down side bolsters in
pilothouse.
b. Install bolts (two port and two star-
board).
c. Run 6 screws both sides in salon.
d. Start in the forward corners above
the windshield and put 3 bolts on
each side of the pilothouse’s over-
head console.
e. Put 3 screws in the center above the
windshield.
f. Install screws above salon door from
outside.
g. When secured, seal all around pilot-
house opening inside.
h. Finish securing aft and reinstall
bolsters, starting from port to star-
board with windshield bolsters.
NOTE: See drawing for screw locations
and quantities. Also, apply sealant to
each individual screw before installing
it.

PartNumber999120001/26/0557 / 56 / 53 Voyager Setup Page 2of11
NOTE: If voids were found above patio
door in Step 3, apply Great Foam to
them.
8. Install sliding salon door, stainless door
cap, and white aluminum drip cap. Seal
under drip cap before installing it.
9. Install cockpit ladder using white 732
multipurpose sealant under bases.
10. Cosmetically seal bridge to deck using
732 multipurpose sealant. Use black
above windows and air intakes and
white where white meets.
NOTE: Leave a 3-inch long void in the
forward corner of black air intake vents
for drainage.
11. Run wire under dash and icemaker.
a. Hook up wet bar and icemaker hoses
b. Hook up mastlight, antennas, and
radar scanner if optioned.
c. Install the rest of the under seat
dividers.
12. If the optional Nautical Structure davit
was ordered, bolt the davit to the cabin
top with the bolts supplied in the Mac
kit.

PartNumber999120001/26/0557 / 56 / 53 Voyager Setup Page3of 11
Section Above Pilothouse
Door
Same as above; different view.
Section Above Pilothouse
Door
Notice how sealant tape goes up and around
section.
Aft of Pilothouse

PartNumber999120001/26/0557 / 56 / 53 Voyager Setup Page 4of11
Section Above Salon Door
Seal using a generous size bead of sealant
top and bottom of sealant tape (SikaFlex-
240).
NOTE: This section is critical because it
keeps any water from entering the top sec-
tion of the salon door.
View Above Aft Salon Door
Deck Above Salon Door
Sealant tape should be placed 3/4” down
from top of deck.
NOTE: It is critical that the sealant tape
and sealant are placed exactly as shown in
the picture.

PartNumber999120001/26/0557 / 56 / 53 Voyager Setup Page5of 11
Starboard Salon Windows
Some boats may already have factory-drilled
holes in these areas. If not, these must be
drilled and screws added: three above
center section and two above aft window.
Forward window section will have a bolt.
Port Salon Windows
Over the two port salon windows behind the
galley, drill five holes spaced as shown.
Forward Port Salon Window
This area will have a bolt.
NOTE: Early serial numbered boats have
two screws if the metal plate and bolt hole
are not installed.

PartNumber999120001/26/0557 / 56 / 53 Voyager Setup Page 6of11
Above Port Salon Window
Run sealant around bolt hole.
Section Above Port Salon
Windows
Section Above Starboard
Salon Windows

PartNumber999120001/26/0557 / 56 / 53 Voyager Setup Page7of 11
Section Above Pilothouse
Door
Notice how sealant tape goes up and around
track section. Seal as picture illustrates.
Starboard View - Front Corner
and Side
Place sealant 3/4” below top of lip on cut-
out.
Port Pilothouse Window
Place sealant 3/4” below top of lip on cut-
out.

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Port Aft of Pilothouse Door
Run sealant around bolt holes.
Above Port Salon Windows
Run sealant around bolt hole.
Back Side of Pilothouse
Run heavy bead of sealant against lip.

PartNumber999120001/26/0557 / 56 / 53 Voyager Setup Page9of 11
Port Aft Corner
Seal around opening for bridge drain hose.
Starboard Aft Corner
Seal around opening for bridge drain hose.

PartNumber999120001/26/0557 / 56 / 53 Voyager Setup Page10of 11
Fastener Locations
Pilothouse:
3 screws across the center windshield
3 bolts each across the port and starboard windshields (on either side of the overhead con-
sole)
3 screws forward of the pilothouse door
3 screws across the pilothouse door
4 screws and 1 bolt aft of the pilothouse door
9 screws and 1 bolt on the port side
4 screws on the aft starboard side
3 screws in the center along the port side steps to the bridge
4 screws on the aft port side
Salon:
6 screws and 1 bolt on the starboard side
6 screws and 1 bolt on the port side
Exterior:
9 screws across the top of the patio door

PartNumber999120001/26/0557 / 56 / 53 Voyager Setup Page11of 11
Fastener Locations
NOTE: All screws and bolts should be installed at the time of assembly. The bolts are
labeled as such; all other fasteners are screws.
9
5 (on 530)
7 (on 570)
9
4
3
34
4
3
3
3
Bolts 3 Bolts
1 Bolt
1 Bolt
1 Bolt
1 Bolt
5 (on 530)
7 (on 570)